RECTIFIER PSR327 USER MANUAL
Contents
1. 2009 ELTEK VALERE DEUTSCHLAND GmbH UM_PSR327_21TE_E_RS O W ELTEK VALERE Rectifier always on PSR327 User Manual Page 12 20 4 3 Charge Characteristic Output Power Diagram The charge characteristic of the PSR327 is a power limited IV characteristic curve in accordance with DIN 41772 DIN 41773 For modules in parallel operation mode a load sharing of about 10 is attained due to a sloping output voltage line 1 at 100 Inom The module is continuously short circuit proof Outout Boost charge voltage 57 6V Vout 1 sloping down enaa 60 lead acid battery M Inom V ol Max output power 2700W DZ Ker 1350 40 C ambient temperature a Short circuit detection at 83 Vonom module automatically switches off a S after 3 seconds After 30 seconds the 22 Pl module automatically tries to restart FF Sa repeatedly 28 Senn 24 Dese A Green hatched aera Operating range of the module 20 16 12 8 4 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 Output current A max output current 56 25A 48Voc Figure 6 Output power diagram example PSR327 48 56 Calculation of the output current lo at different output voltage values using the PSR327 48 65 being the example The PSR327 rectifier provides an output power of Vonom x lonom Ponom 48V x 56 25A 2700W As shown with the output power diagram see figure 6 the nominal output current 56 25A i2. ELTEK VALERE always on RECTIFIER PSR327 SER MANUAL D svan ZIPSRI27 110UDC TEN LEE UM_PSR327_21TE E R5 0 W ELTEK VALERE Rectifier always on PSR327 User Manual Page 2 20 Notes to this manual ATTENTION Read this manual very carefully before installing and commissioning the specified module This manual is a part of the delivered module Familiarity with the contents of this manual is required for installing and operating the specified module The rules for prevention of accidents for the specific country and the general safety rules in accordance with IEC 364 must be observed The function description in this manual corresponds to the date of publishing Technical changes and changes in form and content can be made at any time by the manufacturer without notice There are no obligations to update the manual continually The module is manufactured in accordance with applicable DIN and VDE standards such as VDE 0106 part 100 and VDE 0100 part 410 The CE marking on the module confirms compliance with EU standards 2006 95 EG low voltage and 2004 108 EG electromagnetic compatibility if the installation and operation instructions are followed Supplier A ELTEK VALERE DEUTSCHLAND GmbH GB Industrial Schillerstra e 16 D 32052 Herford T 49 0 5221 1708 210 FAX 49 0 5221 1708 222 Email Info industrial eltekvalere com Internet http www eltekvalere com 2009
3. O unVoltage 7100 Lower Voltage Range psraz7 cov sl 545 NA A Voltage 100 Upper Voltage Range Default PSR3Z7 em 11545 563 ovvonag pp g g zi 10 Et 0 MAX la 4 10 max Output Current PSR State I Status GKL Inclined Characteristic Line Voltage I Temp Lim K Upper Temperature Limit Current hy Temp Lim K Temperature Hysteresis Temperature i del Ua0kCw Uout Ok in del UaOkCce Uout Ok in A k 0 LAN Device Text k 1 KTRAD Temperature adjustment EEPROM Start Adr Word E 00 k 2 k 3 kult Measurement Voltage adjustment Read all k 4 kUI2 Measurement Voltage adjustment EKD k 5 klO Output Current adjustment Typ k 6 n u l k 7 n u Material ID CAN Adr CAN Address gt 0 gt Backplane adr Off Serial Number kla Set Output Voltage PM kla Set Output Current P M Hw ld EEPROM 22 free Address SW d Typ Version Installation Date Running Number M Show Telegram Figure 7 Screenshot PC software for CAN Dongle 2009 ELTEK VALERE DEUTSCHLAND GmbH UM_PSR327_21TE_E_R5 0 W ELTEK VALERE Rectifier always on PSR327 User Manual Page 15 20 5 External Functions If the rectifier works together with a UPC3 DC controller unit the following external functions can be used e Compensation of output voltage e Temperature compensation of charge voltage e Discharge test e Boost charge mode For more information about these functions read th
4. module must be disconnected from mains Make sure that the module is earthed e Do not touch connector pins as they can be charged with dangerous voltage up to 30 seconds after disconnection e Only spare parts approved by the manufacturer must be used 1B Electric Waste Disposal Separate collection is the precondition to ensure specific treatment and recycling of waste electrical and electronic equipment and is necessary to achieve the chosen level of protection of human health and the environment In the case of waste disposal of your discarded equipment we recommend to contact a waste management company 2009 ELTEK VALERE DEUTSCHLAND GmbH UM PSR327 ZI1TE E R5 0 W ELTEK VALERE Rectifier always on PSR327 User Manual Page 6 20 2 General Information The PSR327 rectifier rectifies sinusoidal AC input voltage to DC output voltage The PSR327 is a hot plug in module with rear side connectors and is designed to be mounted in an assembly set 19 sub rack see section 3 2 Due to the state of the art circuitry design the unit has very low losses and therefore very compact dimensions low weight and high power density The PSR327 rectifier can be used in all DC applications with or without battery The rectifier is delivered with factory set default values for lead acid batteries If the rectifier is to be used for NiCd batteries the default values must be parameterized accordingly using a CAN dongle and spec
5. 0 IL Mains input voltage gt 184V 000 Module switches on IV Mains input voltage gt 275V Module switches off self locking It must be manually restarted Output voltage higher than the Module automatically switches off self DC output voltage M locking The unit must be manually adjusted operating threshold restarted Moodie Module automatically switches off It emoa ae Heat sink temperature 280 C automatically switches on when the P heat sink cools down to 70 C Module automatically switches off After 30 sec the module automatically Cooling fan Cooling fan malfunction tries three times to restart If this fails the module switches off and must be manually restarted Module automatically switches off after 3 seconds After 30 seconds the module automatically tries to restart repeatedly Module automatically detects short Short circuit circuit operation by the output voltage value criteria Vout lt 83 of Vnom For factory set output voltage threshold values see section 4 6 2009 ELTEK VALERE DEUTSCHLAND GmbH UM _PSR327_21TE E R5 0 W ELTEK VALERE Rectifier always on PSR327 User Manual Page 14 20 4 6 Threshold amp Default Values The following table shows the factory set threshold default values internally stored in the PSR327 unit for lead acid batteries Default values 110V version 220V version Output voltage Vo Voc 122 6 245 2 Over voltage V gt Vor enn 750 135 0 270 0 Curr
6. ELTEK VALERE DEUTSCHLAND GmbH All rights reserved 2009 ELTEK VALERE DEUTSCHLAND GmbH UM PSR327 ZI1TE E R5 0 Rectifier PSR327 User Manual Page 3 20 W ELTEK VALERE always on The current revision status of this user manual is the following Revision 5 0 Date 2009 07 24 00 First edition 2007 11 06 RTH Minor text modifications 2008 01 04 power diagram and Moritsring reworked 0 revision status numbering XX introduced elate OT 2009 04 29 30 0 Section 4 5 Monitoring reworked 2009 05 15 Minor text modifications section 4 7 Default value setting for NiCd batteries inserted EE Technical specifications Internal decoupling circuit corrected 2009 07 24 2009 ELTEK VALERE DEUTSCHLAND GmbH UM _PSR327_21TE E R5 0 W ELTEK VALERE Rectifier ln PSR327 User Manual Page 4 20 Table of Contents ies ye Aq 5 Eege MSS DIS DOS Al et ne een eee ee eee ee E 5 E EEN a 001 1810 4 E E Stet EE A E E m mmm mmm T 6 3 1408 RAE 2 ED T ere T er eee re 6 E le Re E 6 3 2 Available Options and Assembly Equipment nuur sanseenenseneeneneenesneneenrsernvenensenreneneenrenentenensentenenven 7 3 0 Front vieWw Front side LED panel natens detinee adenine edentate eden 8 IARE 2146 COANEEEIO a a a all een 9 SEENEN eebe 10 36 COMMUNIC diel nn eggs on 10 e AL Ig Ee 11 A ee 11 A OMI VM SIA TE 11 Ue ION WE el LOM E 11 4 3 Charge Characteristic Output Power Diagramm 12 AEDA Lee
7. a ad Gl ol al i 13 e ne ge E UE ei uge 13 4 6 Threshold amp Default AS LIB 14 4 7 Default value setting for NiCd batteries nn sannernensenesneneenrseeneeneneenteneneenteneneenrsnentensnvenseentensnenn 14 ee LEED FUNGI Sarens a A A A AE EEE eene eeen 15 DM UNES AAG A KE EN ASEME UE A aa ei 15 Ze DUE AGO Lal 16 S 61141167 gege eor SA AEA 17 EE 19 Index of Figures Figure 1 DC Power RACK DER PSRIZ7 E 7 Figure 2 DC Power RACK DCR PIRA EEN 7 EE SIRON VOW een E E A a 8 Ee 9 Rearea IONS GE OW terende eben anaal 10 Figure 6 Output power diagram example PSR327 48 56 nnn annnenansenneenenneneenrnennnenrneenenneneenensenvensnennenenn 12 Figure 7 Screenshot PC software for CAN Dongle ae enenenaeenenennnseententeanseeneneentenrnennneerstenssesntersen 14 REWE G EE 19 2009 ELTEK VALERE DEUTSCHLAND GmbH UM_PSR327_21TE_E_R5 0 W ELTEK VALERE Rectifier Sech PSR327 User Manual Page 5 20 1A Safety Instructions Warning Because several components of operating electrical modules are charged by dangerous voltage the Improper handling of electrical modules may be the cause of accidents involving electrocution injury or material damages e Operation and maintenance of electrical modules must be performed by qualified skilled personnel such as electricians in accordance with EN 50110 1 or IEC 60950 e Install the module only in areas with limited access to unskilled personnel e Before starting work the electrical
8. cuit in the line negative output line 80A 80A 30A 20A Input OK green Vo OK green Vo gt red Alarm red 16Bit Fujitsu Collective alarm relay COM NO NC maximum contact load 60Voc 500mA CAN Bus proprietary protocol Operation 20 C to 55 C storage 40 C to 85 C according to IEC 721 3 3 class 3K3 3Z1 3B1 3C2 3S2 3M2 lt 1500m lt 45dB A H t 14 x 19 3U lt Fan cooling temperature controlled r p m monitored AC input DC output and signals DIN41612 M connector 106 3 133 326 5mm 438 mm in combination with an assembly set 19 sub rack approx 3 9kg E E IP20 front panel 1 Front panel RAL 7035 neutral black print RAL 9005 yes EN60950 1 VDE0100 T410 VDE0110 EN50178 EN60146 EN55022 24 ITE class AT EN61000 4 T2 5 C2009 ELTEK VALERE DEUTSCHLAND GmbH UM PSR327 Z1TE E R5 0 W ELTEK VALERE Rectifier always on PSR327 User Manual Page 19 20 8 1 Dimensional Drawings 133 mm 106 3 mm 326 5 mm Figure 8 Module dimensions 2009 ELTEK VALERE DEUTSCHLAND GmbH UM _PSR327_21TE E R5 0 W ELTEK VALERE always on Supplier E ELTEK VALERE DEUTSCHLAND GmbH GB Industrial SchillerstraBe 16 D 32052 Herford T 49 0 5221 1708 210 FAX 49 0 5221 1708 222 Email Info industrial eltekvalere com Internet http www eltekvalere com 2009 ELTEK VALERE DEUTSCHLAND GmbH All rights reserved
9. e UPC3 user manual 6 Maintenance In general the rectifier is maintenance free Exclusively the fan is a component consisting of moving parts By way of precaution a yearly inspection with following checks Is recommended e Mechanical visual inspection e Removal of dust and dirt especially on radiator surfaces e Check for internal dust or humidity It is recommended to exchange the fan every five years Attention Dust combined with moisture or water may influence or destroy the internal electronic circuits Dust inside the unit can be blown out with dry compressed air The interval between the checks depends on ambient conditions of the installed module 2009 ELTEK VALERE DEUTSCHLAND GmbH UM PSR327 ZI1TE E R5 0 ELTEK VALERE Rectifier always on PSR327 User Manual Page 16 20 7 Troubleshooting Symptom Possible reason No output Is mains voltage present Check voltage Mains switched to ON position Check PSR327 module plugged in securely Incorrect polarity or short circuit at the output Check LED V gt on 1 Switch the module off and on 2 Check the settings for V gt see section 4 6 Deviation of the Is the unit operating in current limiting mode Reduce the load output voltage due to overload Is the output voltage setting Vout at the DC Adjust output voltage to nominal controller incorrect values see section 4 6 If an external sensor lead is used for the output C
10. ent limiting Iconst Ac Note The threshold default values can only be changed in combination with a UPC3 DC controller unit If an UPC3 DC controller unit is controlling the power supply unit through the CAN Bus the charge voltage is completely controlled by the UPC3 based on its configuration values and momentary charge state for example temperature compensation boost charge or battery test That means that the values sent from the UPC over CAN Bus have top priority During CAN Bus communication the internally stored values of the rectifier are invalid But when the CAN Bus connection is inactive for more than five seconds e g due to trouble the PSR327 automatically switches back to the internally stored default values In this case it is ensured that the battery is charged in the float charge mode 4 7 Default value setting for NiCd batteries If the rectifier is to be used to charge NiCd batteries the default threshold values must be set according to the individual battery type using a CAN dongle and PC software See section 3 2 Available Options and Assembly Equipment A specific manual is available on request For the adjusting range of the output voltage please see section 8 Technical Specifications Wi Set PSR PSC EEPROM V1 12 A x i Ge PSR C PSC Read EEPROM PSR327 PSR316 PSR308 CAN Adr a Usb Dongle State b a B zn On Laut 100 Default Load Voltage Simulate Monitoring Unit
11. heck voltage is the connection faultless If the module still does not work even though all checks have been done contact your sales agent or the ELTEK VALERE DEUTSCHLAND service department 2009 ELTEK VALERE DEUTSCHLAND GmbH UM PSR327 ZI1TE E R5 0 W ELTEK VALERE Rectifier always on PSR327 User Manual Page 17 20 8 Technical Specifications Type designation Material code AC input Nominal input voltage Nominal input current Input frequency range Power factor Total harmonic distortion Efficiency Internal input fusing DC output Nominal output voltage Nominal output current Nominal output power Charge characteristic line Adjustable output voltage range Default value of the charging voltage factory set 2 27V cell lead acid battery Output over voltage Vo gt factory set 2 5V cell lead acid battery Output under voltage Vo lt factory set 1 7V cell lead acid battery PSR327 48 56 PSR327 60 45 Poko2 7 LOS Ek 7240 1455 101 027 158 00 101 027 168 00 101 027 178 00 101 027 188 00 230Vac 20 e e e 12 9Aac e e e 47 63Hz e e gt 0 99 P gt 50 lt 5 291 lt 16A 6 3 x 32mm vm 48Vpc 60Vpc 108Vbpc 216Vpc 56Apc 0 48V 45Apc 60V 25Apc 108V 12 5Apc 216V 2700W IV characteristic according to DIN41772 DIN41773 power limited 42 62Voc 52 5 78Voc 87 150Vpc 170 295Vpc 54 5Voc 68 1 Voc 122 6Vpc 245 2Voc 60V
12. ial software The nominal output power per unit is 2700 W Up to a maximum of 48 modules can be switched in parallel to increase the system output power or to build redundant power supply systems n 1 principle 3 Type Range Equipment 3 1 Main Data Nominal input voltage 230Vac Nominal input current 12 9Aac Input frequency 47 63Hz Nominal output power 2700W For more specific data see section 8 2009 ELTEK VALERE DEUTSCHLAND GmbH UM PSR327 ZI1TE E R5 0 ELTEK VALERE Rectifier always on PSR327 User Manual Page 7 20 3 2 Available Options and Assembly Equipment Designation Material Code DC Power Rack DCR PSR327 8 1 LV assembly set 19 sub rack 3U incl backplane for three PSR327 48V or 60V rectifiers and one 102 327 318 LVO1 UPC3 48 60V DC controller DCC CB1 connection board included DC Power Rack DCR PSR327 8 1 HV assembly set 19 sub rack 3U incl backplane for three PSR327 110V or 220V rectifiers and one UPC3 110V or 220V DC controller DCC CB1 connection board included 102 327 318 HVO1 DC Power Rack DCR PSR327 10 8 LV assembly set 19 sub rack 3U incl backplane for four PSR327 48V or 60V rectifiers TOO NOA DC Power Rack DCR PSR327 10 8 HV assembly set 19 sub rack 3U incl backplane for four PSR327 110V or 220V rectifiers Cover plate with handle to cover empty PSR slots 1 4 x 19 3U 881 MEC BPL 03 21 B RAL 7035 Monitoring control and signalling uni
13. ions AC input voltage DC output voltage and signals are shown in figure 4 and are defined in the table below 19c 417c 15c 13c 20c 18c 16c 14c 1b 28b 25b 22b 20a 18a 16a 14a 11b 8b 5b 2b 19a 17a 15a 13a Figure 4 Male connectors shown from the rear side of the module Pin assignment of the rear side connector Pin Function 09090900 2D L1 Input 5b N Input lb PE 13a CAN CVSS 13c output voltage sense link CAN H 14a CAN H 14c CAN L Isa CAN CVCC AGND e Hardwarecoding CODE2 Hardwarecoding CODE Collective Alarm NC Collective Alarm COM Collective Alarm H ee LI O C a 6c 1 15 16 17a 17c 18a 18c 19a 19c C a C a C a H 9 Oo 20c__ output voltage sense link 22b Output 25b Output 28b Output 979999 31b Output 2009 ELTEK VALERE DEUTSCHLAND GmbH UM_PSR327_21TE_E_R5 0 W ELTEK VALERE Rectifier always on PSR327 User Manual Page 10 20 3 5 Cooling and Air Flow Direction The unit is cooled with an internal fan The airflow is from the front to rear side The fan is monitored and speed controlled dependent on module temperature To provide sufficient air flow a minimum space see item A in figure 5 of 50 mm is required between the unit and the rear cabinet wall as well as an unobstructed supply of air to the front of the module Figure 5 Module air flow 3 6 Communicati
14. oc 75Vbc 135Voc 270Vpc 40 8Voc 51Voc 91 8Voc 183 6Vpc Default threshold values for charging of NiCd batteries are settable using a CAN dongle and PC software Voltage ripple psophometric acc to CCITT A Dynamic accuracy of the charge voltage Short circuit protection 2009 ELTEK VALERE DEUTSCHLAND GmbH lt 20mVpp lt 1 8mV lt 20mVpp lt 100mVpp lt 200mVpp lt 2 0mV n a n a lt 3 Vnom at load changes between 10 90 10 Inom transient time lt 1 5ms Continuously short circuit proof 1 x Inom UM _PSR327_21TE E R5 0 Rectifier PSR327 User Manual Page 18 20 W ELTEK VALERE always on Type designation Parallel operation Internal decoupling at the output Internal output fuse Standard Features LED signalling Main processor Isolated signalling contact Communications interface Environmental Ambient temperature Climatic conditions Max installation altitude Audible noise Mechanical Type of construction Cooling Connector Dimensions W H D Minimum installation depth Weight Type of enclosure Protection class Colour Compliances CE conformity Compliance to safety standards Compliance to EMC standards PSR327 48 56 PSR327 60 45 PsR327 110 25 PSRSZ7 220 125 Yes max 48 units with UPC3 DC controller unit current sharing lt 10 Inom sloping output voltage line 1 at 100 Inom Yes active low Ve Yes inthe loss decoupling positive output cir
15. on Interface The PSR327 rectifier is equipped with a serial data interface in accordance with the Controller Area Network CAN specification The CAN Bus connection is integrated in the rear side connector Several modules in a system or parallel connection can be controlled and monitored through the CAN Bus by a central UPC3 DC controller unit The following parameters of a specific rectifier unit can be controlled or monitored Output voltage Output current Device temperature Device status Furthermore the rectifier unit receives all threshold values through the CAN Bus from the DC controller unit 2009 ELTEK VALERE DEUTSCHLAND GmbH UM _PSR327_21TE E R5 0 W ELTEK VALERE Rectifier always on PSR327 User Manual Page 11 20 4 Handling 4 1 Storage Modules must be stored in a dry dust free environment with a storage temperature in accordance with the specific technical data see section 8 4 2 Commissioning Note Before commissioning the module make sure that the input voltage corresponds to the input voltage range of the unit as specified on the type plate and that the output voltage of paralleled units matches Carefully unpack the unit Fill the rack beginning with the left slot Put the unit into an empty slot Carefully slide in the unit until the module connector touched the backplane connector Increase the force until the unit fits in completely Avoid using too much force If the unit does n
16. ot fit in begin again at step 3 Secure the module using the two captive screws M3x12 provided with the module Switch ON the module by external MCB M NO Note The PSR327 is serially eguipped with an internal output side decoupling diode This ensures hot plug in capability for the module and enables the operator to add modules under operating conditions Note Before a module is to be removed it must be switched off by the external input fuse Caution After switching off the module the internal capacitors are still fully charged Do not touch connector pins as they can still be charged with dangerous voltage after disconnection 4 2 1 Start up behavior When the PSR327 is switched on without CAN Bus connection first it provides a start up voltage according to the table below The start up voltage is held for 60 seconds than the output voltage steps up to the internal default value PSR327 110V version 220V version Start up voltage VDC 192 0 Default value Vo VDC 122 6 245 2 If a DC controller unit UPC3 is integrated into the system it is powered with the start up voltage after the rectifier has been switched on The output voltage immediately steps up to the value given from the UPC3 unit via CAN Bus If a DC controller unit UPC3 is integrated into the system e g powered by the battery and due to this operating yet the rectifier directly provides the output voltage given from the UPC3 unit via CAN Bus
17. s available at the nominal output voltage 48 0V At other output voltage values e g float or boost charge voltage the output current is corresponding to the following formula lo Ponom Vo Example 1 Float charge voltage for lead acid batteries 24 cells 54 5V lo 2700W 54 5V 49 5A Example 2 Boost charge voltage for lead acid batteries 24 cells 57 6V lo 2700W 57 6V 46 9A 2009 ELTEK VALERE DEUTSCHLAND GmbH UM PSR327 Z1TE E R5 0 Rectifier PSR327 User Manual Page 13 20 W ELTEK VALERE always on 4 4 LED Indications Functions of front panel LED indicators INPUT OK Mains input voltage okay criteria 195Vac lt Vn 265Vac green OUTPUT OK Vout ok criteria Vout 297 of adjusted value amp D Vout gt criteria Vout 2 than adjusted operating threshold ALARM Collective alarm Vin incorrect Vout incorrect module green overtemperature fan failure and short circuit For factory set output voltage threshold values see section 4 6 The module Is equipped with an isolated signalling contact normally open contact The maximum load is 60Voc 500mA The contact is time delayed and reacts after approx 10 sec 4 5 Internal Monitoring Mains input voltage 164V lt Vn lt 195V Linearly decreases output power Mains input voltage lt 164V Module automatically switches off AC input voltage Mains input IL Mains input voltage gt 184V 00
18. t DC controller UPC3 48 60V 301 003 598 02 102 327 408 HVO1 Monitoring control and signalling unit DC controller UPC3 220V 301 003 898 02 DCC CB1 connection board with MSTB screw terminals necessary to connect all measuring control and signalling wires over the 302 DCC CB1 00 backplane of the sub rack to the control unit UPC3 spare part CAN dongle incl PC software necessary to change the internal default values of the rectifier e g for NiCd application eee Nee Monitoring control and signalling unit DC controller UPC3 110V 301 003 798 02 Figure 1 DC Power Rack DCR PSR327 8 1 fully Figure 2 DC Power Rack DCR PSR327 10 8 fully equipped with three PSR327 rectifiers equipped with four PSR327 rectifiers and one UPC3 DC controller 2009 ELTEK VALERE DEUTSCHLAND GmbH UM PSR327 ZI1TE E R5 0 ELTEK VALERE Rectifier always on PSR327 User Manual Page 8 20 3 3 Front view Front side LED panel The PSR327 rectifier is equipped with the following four LED indicators INPUT OK OUTPUT OK Vout gt ALARM For more information about the LED indicators see section 4 4 Two captive screws are used for each module to secure it to the sub rack components of the Figure 3 Front view module 2009 ELTEK VALERE DEUTSCHLAND GmbH UM_PSR327_21TE_E_R5 0 W ELTEK VALERE Rectifier always on PSR327 User Manual Page 9 20 3 4 Rear Side Connection The rear side male connect
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